Why talking saves time, cuts costs and improves quality

Designers are experts in designing, whether they work in consumer goods, machines, instruments, medical devices, automotive, aerospace or anything else. Over the last 40+ years, we have learnt a huge amount about our customers’ industries. Still, we are the first to admit that our expertise lies in prototyping, not design. In particular, our skills and experience are focused on CNC machining, 3D printing (additive manufacturing), vacuum casting, laser cutting, finishing and model making.

Not only do customers come to us with projects from a wide range of industries, they also approach us at every stage – from initial concept development, though proof-of-principle modelling, to visual models, functional prototypes and, in some cases, low-volume production parts. Whatever the scenario, we are always happy to talk to customers so they can gain from our prototyping expertise.

The world of prototyping and the associated technologies are continually evolving. By staying abreast of these developments, we can always advise customers accordingly. The advice we give next year may be different from the advice we give now, as technologies, processes and materials could well have moved on.

Technologies and materials

Indeed, one of the topics we most often discuss with customers is the optimum 3D printing technology and material to use for prototyping a particular part. The answer to this question depends on many factors, including: Is the part for a visual model or a functional prototype? Should two parts be produced separately, or can they be combined? Will high temperatures be encountered? Is material isotropy important? For non-isotropic 3D printing technologies, is the build orientation to be determined by the part’s function? Does the part need to be finished by painting? How quickly is the part required?

If customers consult us early, we can often provide advice about other issues. For example, wall thicknesses, the design of snap fits, whether 3D printed parts or machined aluminium parts can be tapped directly or should be fitted with threaded inserts, and minor changes to part designs that will reduce the lead time.

Critical features

In some cases, parts have one or more dimensions that are critical to the performance. Whether the part is to be produced by CNC machining, 3D printing, laser cutting or vacuum casting, it is important that customers discuss critical features with us so we can achieve the necessary tolerances without undue increases in costs.

The question of whether to use CNC machining or 3D printing is usually straightforward. However, we have worked on projects where the customer was expecting to use one whereas the other offered more advantages. It all depends on the part’s design and its functional requirements.

Small volumes of parts can be manufactured by vacuum casting in polyurethane resin. The process starts with a master pattern produced using SLA 3D printing, then a silicone rubber mould is cast around the master. Small details on the product’s design can make a big difference to the number of parts that can be cast from the mould, so this is where consultation can be very helpful. Furthermore, we can work with customers if, for example, we need to CNC machine metal elements that are to be used for insert moulding with the vacuum casting process.

Medical prototyping

If a customer needs prototype components for a medical device or drug delivery device, and limited patient contact is required, then we can produce these in our dedicated medical cell. We offer a choice of processes and materials for medical prototyping, but designers need to understand the available options before ordering parts.

We are always happy to talk to customers about their projects and we do not charge a fee for this consultancy service. It is just part of what we do! However, the feedback we receive from customers proves the advice and guidance is valuable and makes a difference.

Some customers have found that our input has enabled them to avoid one or more iterations in a design’s development. Frequently, talking to a customer before an order is placed enables us to quote more quickly and reduce the lead time, as it avoids the need for us to raise queries before quoting or when processing CAD model files. By taking our advice onboard, customers often receive parts that perform better or are more reliable.

Benefits

Consulting with us early, whatever stage the project has reached, enables customers to save time, cut costs and improve quality. Usually, these benefits are seen at the prototyping stage but there have also been projects where the final product has also gained from our input.

Wherever you are in the product development cycle, talk to us about your prototyping requirements. We are available over the phone, via video conferencing, by email or we can meet in person. You are also welcome to take a tour of our facilities so you can see for yourself what we do and how we do it. A factory tour provides a great opportunity for you to ask questions about Prototype Projects and our technologies, skills and experience, as well as ask specific questions about your prototype project.

Talk to us

Whatever your prototyping requirements, talk to us on 01763 249760. It won’t cost you anything, but it could save you time in the long run, as well as cutting costs and improving the quality of your prototype parts.